Method of material distribution and apparatus for use in the method

ABSTRACT

A method of material distribution for distributing freeflowing material is provided which consists of transporting the material in bulk from one location to another, siting a mobile bagging apparatus at the second location, unloading the transported material into the bagging apparatus, and bagging the material for use. In a preferred arrangement the mobile bagging apparatus has a receiving hopper for material, a weighing and bagging machine for metering the material into bags in predetermined quantities by weight, and a stitching machine for closing the bags. The material is suitably transported in bulk by transport ship.

This invention relates to an improved method of material distributionand to mobile bagging apparatus for use in the method.

At present, when free-flowing materials such as fertiliser and grain aretransported overseas, the material is first bagged into predeterminedbag sizes and then transported. This has two main disadvantages:

(i) the bags are not completely complimentary in shape so that morespace is occupied than if the material were transported in bulk; and

(ii) the bags are susceptible to damage and therefore there are limitson loading so as to prevent the bags splitting.

However, with present distribution methods there are really noalternatives which will provide the material producers with the productguarantees they require. By bagging the material before distribution theproducers have complete control over the product and any damage to thematerial will only be sustained through mishandling. Thus, beforedistribution, the producers meter free-flowing material into bags,usually measured by volume, and then seal the bags by heat sealingand/or stitching ready for transportation.

An object of the present invention is to provide an improved method ofmaterial distribution which enables material to be transported in bulk.

According to the present invention there is provided a method ofmaterial distribution for distributing free-flowing material comprisingthe steps of transporting the material in bulk from a first location toa second location, sitting a bagging apparatus at the second location,unloading the transported material into the bagging apparatus, andbagging the material ready for use.

Preferably, the method relates to overseas distribution where thematerial is transported in bulk in the hold of a transport vessel.Suitably, in such an arrangement, the bagging apparatus is a mobilebagging apparatus which is temporarily sited on the quay so that thematerial may be unloaded directly from the transport vessel into thebagging apparatus.

The bagging step may comprise metering the material into bags inpredetermined quantities by weight, and closing the bags. In dampenvironments the bags may be polypropylene bags which are heat sealedand stitched. Otherwise, the bags, which may include an innerplasticslining and outer canvas cover, are simply stitched.

The invention also includes a bagging plant for bagging free-flowingmaterial, the plant comprising means for metering the free-flowingmaterial into bags, and means for sealing the filled bags, the baggingplant being readily movable from one bagging site to another baggingsite.

Suitably the bagging apparatus comprises a plurality of interlockingsections each section being of standardised transportable containerdimensions. Alternatively, the bagging apparatus may comprise a singlecontainer adapted to receive free-flowing material for metering into thebags.

A preferred bagging unit comprises at least one transportable container,means defining a receiving hopper for receipt of the free-flowingmaterial, valved outlet means from the hopper, and two parallel baggingruns each including a weighing and bagging machine arranged to receive acontrolled quantity of material via the valved outlet means, stitchingmeans for closing the filled bags, and a conveyor for moving the filledbags from the weighing and bagging machine to the stitching means andready for use.

The invention will now be described by way of example with reference tothe accompanying drawings in which:

FIG. 1 is a perspective view of a bagging plant comprising a pluralityof a first embodiment of bagging unit in use in accordance with theinvention;

FIG. 2 is a perspective view from above of a bagging unit shown in FIG.1 and showing its separate power pack container;

FIG. 3 is a sectional, partially diagrammatic, end elevation of abagging unit (without the separate power pack container) on 3--3 in FIG.4;

FIG. 3A is a detailed drawing of the weighing and bagging machine shownin FIG. 3;

FIG. 4 is a sectional side elevation of the bagging unit shown in FIG. 3on 4--4 in FIG. 3

FIG. 5 is a diagrammatic plan view on 5--5 in FIG. 6 showing analternative bagging unit;

FIG. 6 is a diagrammatic view on arrow A in FIG. 5; and

FIG. 7 illustrates an example of a heat sealing machine that may be usedwith the bagging unit of the present invention.

In FIG. 1 of the drawings a mobile bagging plant 1, for baggingfree-flowing material such as fertilisers, is shown located on a portquay 2. The bagging plant 1 illustrated comprises three bagging units 3each of which are positioned for receiving free-flowing material from adocked transport vessel 4.

The material is moved from the docked vessel 4 to the bagging plant 1 bymeans of a mechanical grab 5 having two scoops 6 pivoted at 7 andarranged so that they may be opened and closed by means of mechanicallevers as desired. The scoops 6 have covered tops so as to deterspillage--the grab may be known construction and therefore, furtherdetails are not provided.

A bagging unit 3 of the first embodiment (see FIGS. 2, 3, 3A and 4)comprises four container sections 8 of standard transportable containerdimensions and a power pack container 66. The four container sections 8are strengthened along their edges for transport and may be lockedtogether in the arrangement shown; namely two upper containers and twolower containers, by suitable fastening means (not shown). The uppercontainers 8 have an open top 9 which is covered by grating 10 andincludes a plurality of roof bow members 11. The roof bow members 11provide support for a removable tarpaulin or like material roof covering12 (FIG. 2). The inside of the upper containers 8 include a slopingpartition 13 defining a hopper inclined downwardly towards asubstantially centrally disposed outlet 14.

The lower containers 8 of the bagging unit 3 each have an openable pairof end doors 15 and an access door 16 formed in the side wall. The lowercontainers 8 each retain a bagging and weighing machine 17 which ispositioned below the outlet 14 from the respective upper container.

The bagging and weighing machine 17 is shown in detail in FIGS. 3, 3Aand 4 and comprises a standard weighing unit 18 of known constructionmounted on a wall of one of the lower containers 8 and a weighing hopper19. The machine has been modified to provide a unique design to ensureaccuracy whilst avoiding spillage and jamming and those features whichdepart from conventional design have been shown in detail whereas theknown features, which form no part of the present invention, have beenomitted for clarity.

The standard weighing unit 18 includes a graduated scale 20 and aweighing support frame 21 on which the weighing hopper 19 is carried.The weighing hopper 19 is positioned below the outlet 14 but is free tomove downwardly relative thereto on filling. It comprises an upper inlet22, a transparent polycarbonate side wall 23, and a bottom wall 24tapering towards a lower outlet 25.

The outlet 14 is normally closed by a valve means 26 including, showndiagrammatically, a first valve 27 to control free flow of material anda second valve 28 cooperating with a restricted opening defined by thefirst valve 27 for trickle flow for final weight adjustment. The loweroutlet 25 consists of two flap valves 29 which close against a centralmember 30 and which are pivoted to the weighing hopper 19 beneath adepending extension 31 of the bottom wall 24. The position of the pivotpoints protects them against becoming jammed in use. The movement of thevalves 27, 28 and 29 is effected by respective double-acting, hydrauliccylinders 32; only those for flap valves 29 being shown.

Suspended below the valved lower outlet 25 is a filling chute 33 havingbag support clamps 34 pivotally mounted thereto as shown which aremovable by means of double-acting hydraulic cylinders 35. The fillingshute 33 is supported by means of a frame 36 extending downwardly fromabout the outlet 14 and which surrounds the weighing hopper 19.

Reverting to the standard weighing unit 18 it will be seen that this isprovided with three controlling limit switches 37, 38 and 39. Switch 39is a zero and is effective to ensure: closure of the flap valves 29 asshown to left in FIG. 3A, and release of the bag clamps 34 also as shownto the left in FIG. 3A. In this position the weighing machine may onlybe operated by a user clamping a bag on the filling chute 33 andactuation of a safety operation switch (not shown). This will then causevalves 27 and 28 to open so that material flows through outlet 14 intothe weighing hopper 19 until the weight reaches limit switch 37. Thisswitch causes closure of the valve 27 to reduce material flow as itapproaches the desired weight. When switch 38 is tripped the valve 28 isclosed stopping material flow completely and providing an accuratemeasured load whereupon the flap valves 29 are released to fill the bagclamped below.

In addition to the bagging and weighing machine 17 the lower containers8 also each include a slatted endless conveyor 40 disposed beneath themachine and provided with lateral guides 41 so that, when filled, a bag42 may be passed to a stitching station 43. the stitching station 43includes a proprietory stitcherm suitably a DOBOY (Registered TradeMark), which is activated automatically as each bag is fed into themachine. If desired, for example in damp environments a heat sealingstation may be provided between the bagging station and the stitchingstation.

A preferred heat sealer illustrated by way of example in FIG. 7 is aproprietory heat sealer marketed by The Thames Packaging EquipmentCompany under the trade mark SAXON. The sealer 44 receives the mouth ofthe bag 42 as it passes along conveyor 40 sealing the mouth of the bagby the application of heat. The heat sealer 44 suitably may be heightadjustable on a vertical pillar 45 by means of turn wheel 46.

Although a SAXON heat sealer and a DOBOY stitcher have been shown as anexample it will be understood that any form of suitable heat sealing andstitching assembly may be used.

Outside of the container sections 8 it will be seen that the endlessconveyors 40 feed the bags 42 to respective conveyor elevators 54. Theelevators 54 have a first section 55 receiving bags 42 from theconveyors 40 and a second section 56 feeding the bags onto the transitvehicle 57. The first section 55 is preferably a plain conveyor althougha slatted conveyor is illustrated in FIGS. 1 and 2: the second section56 may be slatted or plain. In oder to provide continuity of the processthe second section 56 is angularly adjustable about two perpendicularaxes so that it may vary its upwardly inclined attitude and slew fromside to side, for example during the transition from loading one vehicleto loading another.

It will be seen from the above that each bagging unit includesconstituent parts in duplicate. The reason for this is that thecontainers 8 are narrow in width and therefore, if two containers werenot locked together, there would be a danger of free-flowing materialspilling over the sides of a single container during supply of materialto the bagging unit. Moreover there are preferably three units as shownin FIG. 1 to provide for fast bagging.

In FIGS. 5 and 6 an alternative embodiment is illustrateddiagrammatically. In this second embodiment the bagging plant 60comprises a single container 61 having parallel bagging runs 62 alongeach side. Each run consists of a weighing and bagging station 63 and astitch station 64 with a sealing station therebetween if desired. Thedetail of the weighing and bagging machine and the stitching machine maybe as shown and described in respect of the first embodiment. Inaddition the single container includes side access doors 65 for each run62 and a rear generating station 66 accessible by means of openable enddoors 67. So that the bagging runs 62 may be operated independently ofone another each run extends to an individual openable end door 68.

As explained above, with a single container width, there is a danger ofmaterial spilling over the sides. In this second embodiment the materialhopper is provided by side walls 69 which are hinged to the top of thecontainer 61 and are movable to a position indicated by dotted lines 70by means of hydraulic cylinders (not shown). In order to close the gapsbetween adjacent side walls 69 each side wall is provided with a hingedflap which overlaps the adjacent side wall and is held against the saidside wall by the pressure of the material within the hopper. The gratingof the first embodiment suitably is replaced by a nylon mesh indicatedby dotted line 71 and a tarpaulin may be provided if desired.

In use, in either embodiment, a contract is obtained and then, ratherthan shipping material already bagged, the material is loaded in bulkinto a bulk transport vessel for transportation to the nearest, or mostconvenient port, for the required destination. The advantage of bulktransit is that much more material can be handled since, with materialthat has already been bagged, more space is occupied and there arerestrictions on loading in order to prevent bag breakage. At the sametime a mobile bagging plant in accordance with the invention istransported to the port in question for assembly on the quay just priorto the arrival of the transportation vessel. The bulk material is thenunloaded from the vessel by means of one or more grabs 5 which depositthe free-flowing material into the receiving hoppers of the baggingunits: in the first embodiment the grab may be provided in the powerpack container 48. The material flows from the receiving hopper, throughrespective valve controlled outlets 14, to the bagging and weighingmachines 17. Once the weighing hopper is full, the valved outlet 14 isclosed, the flap valves 29 opened to fill the bag, the full bag passedfor stitching and heat sealing if necessary and then a new bag suspendedfor filling. The full bags are then loaded onto waiting vehicles fortransportation to their destination at a rate of about six bags perminute; approximately the same rate as it would take to unload readybagged material.

If the weather turns bad during unloading the hatches on thetransportation vessel would be closed and tarpaulins placed over thematerial loading hopper. Bagging is then continued until the supply offree-flowing material retained in the hopper is exhausted. The baggingunits of the present invention are provided with their own generators sothat the units are totally self-sufficient these may either be separateunits or part of the same unit.

Once unloading and bagging of the material has been completed the mobilebagging units are moved from the quay, in the case of the firstembodiment disassembled and, if necessary, moved to another port wherethey are required. The standard container size of the modules of thebagging units means that the bagging units are readily transported byexisting road, rail and sea methods.

We claim:
 1. A mobile bagging plant for bagging free-flowing material inbags, comprising:at least one transportable module of standard shippingcontainer dimensions and being readily movable from a first site to asecond site, said module being compatible with other like standardizedcontainers so that said module is stackable on and among said other likecontainers; and a bagging apparatus housed in said module, said baggingapparatus includingan inlet means for receiving the material andclosable by a first valve means, weighing means including a receptaclehaving an inlet and an outlet, and means for measuring the weight of thematerial within the receptacle, said inlet of said receptacle beingpositioned to receive material from said inlet means, second valve meansfor closing said outlet, bag retention means for positioning bags undersaid outlet of said receptacle when said second valve means is openedand for removing the bags after the bags have been filled, control meansfor closing said first valve means and then opening said second valvemeans when the weight of the material in said receptacle reaches apredetermined weight such that predetermined weights of material are fedinto the bags from said receptacle, and closure means for closing thebags after filling.
 2. A bagging plant according to claim 1 wherein theplant comprises a plurality of interlocking modules, each said modulebeing of standard transportable shipping container dimensions.
 3. Abagging plant according to claim 1 wherein said closure means comprisesa stitching machine.
 4. A bagging plant according to claim 2 wherein theplant comprises two lower and two upper interlocked modules, said twoupper modules defining a material receiving hopper.
 5. A bagging plantaccording to claim 1 wherein said module comprises a plurality of flapshingedly connected to a top end thereof, said flaps being extendable todefine a receiving hopper for material for subsequent delivery to saidinlet means.
 6. A bagging plant according to claim 4 wherein twoparallel bagging runs with respective conveyors extending between aweighing and bagging station and a stitching station are housed in saidmodules.
 7. A method of distributing free-flowing material, comprisingthe steps of:transporting free-flowing material in bulk and a baggingapparatus with weighing means and housed in at least one transportablemodule of standard shipping container dimensions from a second locationto a first location, said module being compatible with other likestandardized containers so that said module is stackable on and amongsaid other like containers; siting said bagging apparatus at said firstlocation; supplying the material to the bagging apparatus; weighing thematerial into batches of predetermined weight in said receptacle;positioning bags to receive the batches from said receptacle; anddelivering the batches of material into the bags.
 8. A method accordingto claim 7 wherein the bags are closed by stitching at a stitchingstation spaced from a bagging station at which material is metered intobags. .Iadd.
 9. A mobile bagging plant for bagging free-flowing materialin bags, comprising:a first transportable module of standard shippingcontainer dimensions and being readily movable from a first site to asecond site, said first module being compatible with other likestandardized containers so that said first module is stackable on andamong said other like containers; a second transport module of standardshipping container dimensions and being readily movable from a firstsite to a second site, said second module being compatible with otherlike standardized containers so that said second module is stackable onand among said other like containers; a receiving hopper formed in saidsecond module, said second module being interlockable with andpositionable above said first module; and a bagging apparatus housed insaid first module, said bagging apparatus includingan inlet means forreceiving the material from the receiving hopper and closable by a firstvalve means, weighing means including a receptacle having an inlet andan outlet, and means for measuring the weight of the material within thereceptacle, said inlet of said receptacle being positioned to receivematerial from said inlet means, second valve means for closing saidoutlet, bag retention means for positioning bags under said outlet ofsaid receptacle when said second valve means is opened and for removingthe bags after the bags have been filled, control means for closing saidfirst valve means and then opening said second valve means when theweight of the material in said receptacle reaches a predetermined weightsuch that predetermined weights of material are fed into the bags fromsaid receptacle, and closure means for closing the bags afterfilling..Iaddend. .Iadd.
 10. A bagging plant according to claim 9wherein said closure means comprises a stitching machine..Iaddend..Iadd.11. A bagging plant according to claim 9 wherein the receivinghopper comprises a plurality of flaps hingedly extendable to define thereceiving hopper for material for subsequent delivery to said inletmeans..Iaddend. .Iadd.12. A bagging plant according to claim 9 includingtwo parallel bagging runs with respective conveyors extending between aweighing and bagging station and a stitching station..Iaddend. .Iadd.13.A method of distributing free-flowing material, comprising the stepsof:transporting free-flowing material in bulk, a bagging apparatus withweighing means and housed in a first transportable module of standardshipping container dimensions, and a receiving hopper formed in a secondtransportable module of standard shipping container dimensions, from asecond location to a first location, said modules being compatible withother like standardized containers so that said modules are stackable onand among said other like containers; siting said bagging apparatus atsaid first location; locating the second transportable module above saidfirst module; supplying the material to the receiving hopper; meteringthe material from the receiving hopper to the bagging apparatus;weighing the material into batches of predetermined weight in saidreceptacle; positioning bags to receive the batches from saidreceptacle; and delivering the batches of material into thebags..Iaddend. .Iadd.14. A method according to claim 13 wherein the bagsare closed by stitching at a stitching station spaced from a baggingstation at which material is metered into bags..Iaddend.